Manufacturing
Warping, covering, rubber warping, production, finishing, checking, packing, and dispatch. Every meter follows this path before it leaves Sonipat.
2.5M m
Daily capacity
Elastics, tapes & webbings
300
Production machines
Woven, knit, crochet, braid
20+
Checking machines
AI + manual inspection
2M m
Checking capacity / day
Before packing release
Process flow
This is the real sequence on our floor: yarn beams and covered rubber beams are prepared first, then constructions are woven, knitted, crocheted, or braided, heat-set on hot rollers, checked, packed to preference, and dispatched.
Stage 01 / 08
Yarn beams prepared
01
Yarns are warped onto beams under controlled tension, so every end that reaches the loom is even, aligned, and ready for production.
Next → Covering
Stage 02 / 08
Yarn-covered rubber bobbins
02
Rubber or spandex cores are wrapped with polyester, nylon, or cotton on covering machines. These covered bobbins feed the rubber warping stage and give the core strength, controlled stretch, and heat resistance.
Next → Rubber Warping
Stage 03 / 08
Covered rubber beams
03
Covered rubber bobbins are warped into beams with matched elongation and density. These elastic beams sit alongside yarn beams on the production machines.
Next → Production
Stage 04 / 08
Elastics, tapes & webbings
04
Elastics, tapes, and webbings are made on their specific machines based on the construction: woven, knitted, crochet, or braided. Machine type follows the product, not the other way around.
Next → Finishing
Stage 05 / 08
Hot rollers remove shrinkage
05
Finished elastic is run over hot rollers to heat-set the tape and remove shrinkage. This prevents curling in the garments and products where the elastic is later used.
Next → Checking
Stage 06 / 08
AI + manual inspection
06
AI checking and manual inspection run across more than 20 machines, with checking capacity over 2.5 million meters daily. Width, defects, and meterage are cleared before packing.
Next → Packing
Stage 07 / 08
Client-preferred formats
07
Checked material is packed to client preference: continuous rolls, cut pieces, layered packs, or retail formats such as hanks and spools.
Next → Dispatch
Stage 08 / 08
Export-ready consignments
08
Cleared lots are palletised, documented, and dispatched. Final random audits from the quality system still apply. A fail holds the entire lot for recheck before anything leaves the dock.
Packing options
After checking, material is packed to client preference. One construction can leave as rolls for a cutting floor, pieces for an assembly cell, or retail hanks for a merchant.
Rolls
Continuous winding for garment and industrial lines that feed meters.
Cut pieces
Pre-cut lengths for assembly cells that need fixed piece counts.
Layered packs
Flat layered packing for orderly picking and clean carton density.
Hanks & spools
Retail-ready hank and spool formats for merchants and small-run buyers.
Why finishing matters
Elastic that skips heat-setting can curl or shorten after sewing. Our finishing line runs the tape over hot rollers so residual shrinkage is removed in-house, not in your garment or strap.
Why checking is separate
Checking is its own department: AI assist plus manual inspection across 20+ machines. Only cleared meters move into packing. Dispatch still samples again, and a fail holds the full lot.
See the five quality gatesPlant visit
